Method for catalytic cracking of hydrocarbon oils



2,452,172 IETHOD FOR CATALYTIC CRACKING 0F HYDROCARBOH OILS Filed 001'.. 17,

Oct. 26, 1948. H. B. wlLLARD 3 Sheets-Sheet 2 IN VEN TOR. HERBERT B. wlLLRD HIS 'ATTORN EY Oct. 26, 1948. H. a. wlLLARD METHOD FOR GATALYTIC CRACKING 0F HYDOCARBON OILS 3 She'ets-Sheet 3 Filed Ovt. 17, 1945 NTRMBDIATE CHTALYST LE VEL NVENTOR. HERBERT B. WlLI-.RD

His .ATTORNEY LO W' CATA LYS'I. LEVEL presence of'soli'd catal of hydrocarbons by s its activity.

' In one system of is maintained in actors,

by pas the reactors while theremainin'g reactors are befor, or "TCC process,

volume, thereby providing vcatalyst in the' rea generation zones, the

allor a portion of the form results over .ishes in efliciency.

Patented Oct-2 6, 1 948 uNi'i'isDll STATES Marilou FOR cA'rALY'rro caaclmvo'or nynRocAaBoN o iLs f,

herbert Wiliam, rm Arthur,

to Gul. irorporation, poration oi' Pennsylva Application aantal-17, 1945, serial'No; 622,812

4 claims.

This invention relates to an improved method for subjecting hydrocarbons to` the. yactionjiif solid catalytic materials, and more. particularly to an improved method for effecting cracking of hydrocarbonV oils at high temperatures inthe ysts.

It is common to promote pyrolysis'or cracking temperatures, to contact withsolid catalysts. In most cases such contact. results ,innthe formation of products of reaction', such as `carbon,.which deposit on the catalyst and reduce its activity,

so that it must be regenerated in order to restore catalytic cracking the catalyst fixed beds lying in a series of resemicontinuous operation being achieved singhydrocarbon. vapors throughone of ing .regenlerated, and periodically` transferring the In another system, known as the Thermocontinuity of operation is attained by maintaining a "moving bed of solid catalyst inthe reactionv zone lying in the path of the hydrocarbons,` withprovisions for continuously introducing catalyst to the upper part of the bed, "for removing thebottom of the bed, for conveying the spent `catalystto a', regenerator and forreturning regen' erated catalyst to the upper part of the bed lying within the reaction zone. Inthis character it has been necessary as apractical matter to'maintain the a.- space velocity which must be determined either in the light of the initial degree of activity of the fresh catalyst or in the light of a somewhat reduced activi-ty representing an average rof 'catalyst in the cycle. as the cold volume the activity of the Space'veiocity is defined of oilper hour passing through the reaction zone divided by the vol ctionfzone, and serves as a measure of reaction time.

However, regeneration isy never complete 'in practice. As'the catalystA remains in the unit, passing repeatedly through the reaction and recommonly the system is gradually reduced, untilK finally a point is reached wher catalyst and replace it with fresh catalyst. Whileit is possibleto maintain a uniform space velocityl over extended periods, without changing the hydrocarbon throughput of the unit, it has been impossible to achieve uniwithout reducing th e hydrocarbon throughput las the activity of the regenerated` catalyst diminubjecting them, at elevated flow of hydrocarbon vapors from one'reactor to. another,

spent catalyst from prior operations of bed at a constantV ume of the activity of the catalyst in e it is necessary to discardextended operating periods by the present invention isl An-'obiect achieved the provisionof a -m -J formity of operating 'resultscan be maintained over extendedy periods", in a method 'of the charl5v acter indicated, than has been true in priorfoperations.

A further obi tion is the provision of a m formity of operating conditions i fective and inexpensive manner.

My invention 'has for tional 'improvements in operating hereinafter be foundz-to/obtain.

- In accordance Ywith my invention reaction zone adapted to receive a a bed oi solid vcatalyst lying inthe Y means for introducing fresh or regenerated cataect achieved bythe present 'invenf-f ethod 'foi-'securing uni.-

path -of the 20 ,moving it vfrom the bott vide for increasing the catalystbed as the act catalyst/falls, without hydrocarbons through While, in theory,

vide for continuously increasing the volume of the catalyst bed,`I have found that in practice the' rate atwhich the activity .of the" catalyst diminishes in efficiency is usually slow,4 and that the conversion zoneg' substantial unifo tained by increasing thevolume or depth: of thel catalyst bed at more or less regular 'intervals'in incrementsdepending upon the diminution" in activity ofthefcatalyst. 1 I

Thus, in Aa specific embodiment of an apparatus. f or carryingl out the method-otmy .invenntion a 'supply of fresh o maintained ina zone o 1 reaction zone and preferably forming a partpi 40 the reaction vessel. Catalyst is permitted to iiow downward from this hopper into th^e` vreaction chamberor zone through a lseries of downflow conduits adjustable in length, with provision lfor *raising and loweringthe lower endsof the downflow conduits to establish a desired level of catalyst;bed lying in the path of the hydrocarbons in the-reaction chamber. j

' Ina simple and preferred form, the downow conduits comprise la plurality of fixed downflow pipes with extension sleeves mounted thereon,

' the sleeves being supported as .which can be raised or lower desired position from outside ure makes it possible 'to vary ythe depth and urne of the catalyst bed over a fairly wide range, without interrupting the iiow of hydrocarb'ons andthe course of' the reaction or conversion taking place. i

.In accordance wi ised and xed in any thel vessel. Such a th my invention, the operation commenced with the catalyst downilow conethod whereby greater unif n a s impleleifurther objects/suolii addiresults as'may' I provide a nd maintain rocarbon vapors' to be treated or cracked, with lyst to the upperportion ofthe bedand for rev om of the bed. and I prcdepth or volume ofthe' l ivity' of the regenerated L interrupting theilow ofl it would-be desirabito "prdrmityof operation can be ob-.

r regenerated catalystis r hopper -lyingabove the.

a unit from a frame tumllmntanons.

.. 'I aeaafva 3 duits in their extended positions. the lower ends of these" conduits establishing a minimum catalyst bed volume adapted to give the optimum space s velocity in terms of fresh catalyst, namely, a catalyst of maximumactivity. As the operation proceeds and the activity of the` catalyst gradually diminishes in efficiency, the downflow pipes are periodically shortened,` thus increasing the depth materials.` A grate or a perforated plate lior of the bedin proportion to the loss fin catalytic activity, until finally the conduits areshortened as far as possible and the catalyst bed reaches Y the maximum volume permitted by the 'strucf- By properly proportionlng the downflow conduits and the extension sleeves mounted thereon,

it is possible to provide f or increasing the volume of thecatalyst bed to a point where substantial uniformity of operation can be obtained upto af `point where the activity ofthe cataly'stapproache:

" the minimum activity -consistent with emcient operation. In short, in the preferred design, the

maximum volume of the catalystbed permitted by the construction should give the desiredspace velocity when the catalyst approaches such a low y level of activity that further enlargementof the bed volume would bejundesirable. When-such p satisfactory cycle from all points of view can be worked out with a catalyst -bed or path or f ldw of the orderof two/to four feet, Thel catalyst bed can be increased from, say,`a low of two feet 'to At such a high of twenty-eightfeet or more. time, after the catalyst has diminished in activity to apoint where its further use wouldbe uneconomlcal, the operation is then interrupted,

' fresh catalyst suppliedto the.system, and the operation is again 'renewed with the bed at minimumvolume as before.

Proper'velocity ofthe reactant material through the contact mass is important in effecting a high yield of the desired products and in minimizing side and secondary reactions. Thus by varying higher and more uniform yield .of thedesired products throughout the entire cracking operations.

In order that my invention may be fully under l stood, I now describe, with reference .to the drawl ing'accompanying and forming part of this specication, a preferred embodiment of an apparatus for carryngoutthe 'method of my invention. In

l these drawings,

Figure 1 ls -a vertical cross sectional view kof an apparatus for carrying out the invention,

" Figure 2 is a detailed view of the operating mechanism, y

-Figure 31s a top Plan view,

Figure 4 is a detailed vertical cross section of the ,reaction chamber, wherein the tubes are in a dierent positionthan inFigure 1,

Figure` 5 is atransverse cross section taken on line 5--5 of Figure 4,

Figure 6 is a detail View partly in section of one of the elements shown in Figure 1.

Referring to Figure 1, there is shown a catalyst vessel Ill of the vertical type provided with a valved inlet Il for the reacting hydrocarbon materials and a valved outlet l2 for the reacted maximum volume has been reached, it would from "wall to wall within thereactor in a direction normal to theduct 30. Each of the troughs the bottom as shown in Figure 6. In the duct ducten. new ont'throgh the annees sz, into the into the catalyst bed lli.

I -The reaction chamber 'Il isadapted' to 'receiveV l catalytic material of any solid pulverulent type such as natural rarticial clays or gels, silica ,y or 'alumina impregnated with metallic oxides or salts, or the like. The catalytic'material is withdrawnfrom the reaction chamber Il through the grate i3 and an outlet conduit ii controlled by a slidevalve i1.

The catalyst may tributing hopperl be introduced into the I dis- |8 of the reaction chamber the catalyst'drops by gravity through catalyst feed pipes 20 yand telescopically extensible feed pipes 2| into the 'ref action chamber Il( -The top of the Icatalyst `bed l I5 will not rise above the bottom of the extensible pipes.2| feeding the catalyst to this bed.

"` Downiiow catalyst feed pipes 2D arel attached` 24 to which are also attached the telescoping pipe sleeves 2|. Each rod 23 passes through astufling box 25 and a'sleeve-26, which is attached to partltion '22 at the top of the reaction chamber ll and is provided with an expansion joint 21.v the space velocity in the reaction zone without l' interrupting the flow of-hydrocarbons, I obtaina Figures 2 and 3 show the mechanism wherein a chain operated handwheel 23'keyed on a shaft .29 operates througha worm drive 30, shaft 2|,

A.worm drives 32 and 33, and drive shafts 3l and 35,

- length adjustment. The level of the catalyst in the reaction chamber il is indicated on scale I2 by a pointer 43 fastened to a roller chain lil. The

weight of rod 23, support 24 and sleeves 2|- are thus balanced by' the counter-weights and the system made easily movable by rotation of the wheel 28 in'any suitable manner.

Mechanism for lowering and raising pipe sleeves 2| is connected with operating platform 46 which is outside the reaction chamber I4.

Figure .4. illustrates the variation in level of the catalyst bed, the high level l1, an intermediate level i8 and the low level 43 being diagrammatically indicated in the reaction chamber.

Figure 5 is av transverse cross section to show has-the form of a gable roofed channel open at l each trough-5|, there is an orifice I2. The reactant hydrocarbons enter .inlet of the space-under troughs 5| Aund then flow upwardly I8 of the reacting chamberfll through the catalyst inlet tube i3 from ahoppei; (not` shown) above thecatalyst tower l0 which is Apreferably closed to the 'atmosphere -to prevent the' escape of grises'. From the distributing hopper the arrangement of the catalyst feed pipes 2I in the reaction chamber shown in Figure 4.

In employing the apparatus-illustrated for the catalytic cracking of hydrocarbons, a catalyst is passed continuously through the reaction chamber I4 and a definite level of catalyst bed I5 is established therein from, say, about 2 to 4 feet deep. The catalyst is poured into the inlet tube I 9 and gravitates to the hopper I8. From this hopper I8 it gravitates into the downow feed pipes and extensible telescopic pipe sleeves 2| which extend into the reaction chamber I4.

The top of the catalyst bed I5 in the reaction chamber I4 is maintained substantially at the bottom of the extensible catalyst feed pipes 2| feeding the catalyst to this bed. The spent catalyst is continuously withdrawn through outlet conduit I6. This spent catalyst is then regenerated and returned to the reaction chamber I4 and the above cycle is repeated.

As the activity of the catalyst bed I5 diminishes, the catalyst bed I5 -is progressively increased in height and maintained at this level until the activity of said catalyst bed I5 undergoes further diminution. This process of increasing the catalyst bed I5 in reaction chamber I4 continues until the maximum catalyst level 41 is reached. Cracking is then continued until the activity of the catalyst 41 has diminished in elciency to a point where further operation would be ineflicient. At

that time cracking is discontinued. the spent catalyst is discharged and new fresh active catalyst charged into the system.

The variation of the catalyst bed level I5 is accomplished without interrupting the cracking operation, thereby a rapid, uniform rate of cracking may be maintained without substantially increasing the cracking temperature and thus eliminating reaction products different from those derived.

While the invention has been herein disclosed in what are now considered to be the preferred forms, it is to be understood that it covers all changes, modifications and adaptations within the scope of the appended claims.

What I claim is:

1. In a process of contacting hydrocarbons with solid catalytic material by continuously passing a stream of hydrocarbons through a moving bed of said catalyst, wherein active catalyst is continuously supplied to the top of said catalyst bed, spent catalyst is continuously withdrawn from the bottom of said catalyst bed, and the spent catalyst is regenerated and returned to the top of said catalyst bed. the improvements which comprise reducing the space velocity of the hydrocarbons through said catalyst bed by increasing the volume of the bed as the average activity of catalyst entering the catalyst bed diminishes, without interrupting the flow of hydrocarbons therethrough, while maintaining otherwise substantially uniform operating conditions throughout the process, thereby obtaining a substantially uniform rate of conversion and yield of products. 2. In a process of contacting hydrocarbons with solid catalytic material by continuously passing of hydrocarbon vapors through a moving bed of said catalyst, wherein active catalyst is continuously supplied to the top of said catalyst spent catalyst is continuously withdrawn from the bottom of said catalyst bed, and the spent catalyst is regenerated and returned to the top of said catalyst bed, the improyements who comprise initially establishing a minimum volume of catalyst bed which will give an optimum hydrocarbon space velocity for catalyst of maxi'- mum activity, thereafter reducing the space velocity in proportion to the progressively diminishing average activity of catalyst entering the catalyst bed by progressively increasing the volume of the bed, thereby obtaining optimum space velocities for catalyst of diminishing activity without interrupting the iiow of hydrocarbon therethrough, while maintaining otherwise substantially uniform operating conditions throughout the process, thereby obtaining a substantially uniform rate of conversion and yield of products. 3. A continuous method for catalytically cracking petroleum hydrocarbons which comprises continuously passing hydrocarbon vapors upwardly through a reaction chamber containing a bed of solid catalyst, continuously withdrawing the vapor of the cracked hydrocarbons from the reaction chamber above the level of the catalyst bed, continuously withdrawing spent catalyst from the lower end of the catalyst bed, regenerating said spent catalyst, continuously adding said regenerated catalyst to the top of the catalyst bed, and gradually increasing the depth of the catalyst bed without interrupting the fiow of the hydrocarbon vapor therethrough in proportion to the gradually diminishing activity of said regenerated catalyst so that the decreased activity of the catalyst will be offset by the increased amount of the catalyst which the incoming hydrocarbon vapors are forced to contact.

4. A continuous method for catalytically cracki ing petroleum hydrocarbons which comprises establishing a minium solid catalyst bed in the reaction chamber which will give an optimum hydrocarbon space velocity for a catalyst of maximum activity, continuously passing hydrocarbon vapors upwardly through the said bed of catalyst, continuously withdrawing the vapor of the cracked hydrocarbons from the reaction chamber above the level of the catalyst bed, continuously withdrawing spent catalyst from the lower end of the catalyst bed, regenerating said spent catalyst, continuously adding said regenerated catalyst to the top of the catalyst bed, and gradually increasing the volume of the catalyst bed without interrupting the iiow of the hydrocarbon vapors therethrough in proportion to the gradually dlminxshmg activity of said regenerated catalyst so that the decreased activity of the Catalyst will be offset by the increased amount of the catalyst which the incoming hydrocarbon vapors are forced to contact.

HERBERT B. WILLARD.

REFERENCES CITED The following references are of record in the ille of this patent:

FOREIGN PATEN'S Country Date Great Britain Nov. l2, i396 Number Date Mar. 5, 1901 Oct. 13, 1942 Jan. 25, 1944 Mar. 14, 1944 July 11, 1944 Number 

